Two part molded part useful as a mixer for viscous curable materials

ABSTRACT

The present invention relates to articles comprising a plurality of molded hollow parts ( 11 ) having different central axis ( 14, 15 ) through the hollow elements, further having passages in walls of the hollow parts transverse to the central axis of the hollow parts. The present invention also relates to methods applying two part curable materials to substrates using the molded parts of the invention as mixing elements.

FIELD OF INVENTION

The invention relates to articles comprising a plurality of moldedhollow parts having different central axis through the hollow elementsfurther having passages in walls of the hollow parts transverse to thecentral axis of the hollow parts. The invention also relate to methodsof applying two part curable materials to substrates using the moldedparts of as mixing elements.

BACKGROUND OF THE INVENTION

Two part curable compositions are used in a variety of applications suchas adhesives, coatings, foams and the like, where rapid cure is requiredfor the application, especially where the two parts are not shelf stablewhen in contact with one another. Shelf stable means that thecomposition does not cure in storage. Two part curable compositionswhich exhibit viscosities may be difficult to mix and apply. Examples ofsuch systems are disclosed in WO 2012/151086 and WO 2012/151085,incorporated herein by reference in their entirety. This is especially aproblem where the two parts are mixed in a relatively high volumetricratio of one part to the other. When the two parts are mixed in highvolumetric ratio of a one part to the other, the two dissimilar partsmay be stored in a bag in bag tube, wherein the smaller volumetric partis stored in a bag disposed in the higher volumetric part, one of thebags is generally disposed along the outer wall forming the tube. Thebag forms a barrier to contact of the two parts. This configurationallows for utilizing any volumetric ratio without concern for the sizeof the material tubes and their ability to work with standard two partmixers. Common concerns include high back pressure of the curablematerial and thorough mixing of the materials. If the back pressureresulting from introducing highly viscous material into the mixer usedis too high, the curable materials will not pass through the mixingchamber and cannot be applied. If the two parts are not adequately mixedthe curable material will not cure in a manner desired. A complicatingfactor is that many two part composition are applied in remote locationsor by consumers, where there is limited or no access to applicatorscapable of applying sufficiently high pressures to overcome the backpressures and thoroughly mix the parts, many common manually driven orbattery driven applicators do not have the capability to overcomebackpressures resulting from trying to pass a highly viscous materialthrough mixers capable of properly mixing such compositions.

Complex mixing systems have been developed to address these problems,see for example, EP 1,189,686; and EP 1,830,070 and EP 2,011,562incorporated herein by reference in their entirety. Such systems can becomplicated to use or costly to manufacture.

What is needed is mixer systems that can thoroughly mix highly viscoustwo part compositions using manual and battery operated applicatorswithout creating unacceptable back pressures, which are easy to use andcan be manufactured in a cost effective manner. What are needed aremethods for applying viscous two part curable systems utilizing suchmixing systems.

SUMMARY OF THE INVENTION

The invention relates to articles comprising a plurality of moldedhollow parts having different central axis through the hollow elementsfurther having passages in walls of the hollow parts transverse to thecentral axis of the hollow parts. The invention also relates to methodsof applying two part curable materials to substrates using the moldedparts as mixing elements.

The invention relates to articles comprising: two parts each part havingtwo or more sections connected together wherein each section is formedfrom one or more molded materials, which form the periphery of a hollowstructure having a proximal end, a distal end, a cross section and openpassages in the molded material on the periphery of the hollowstructure, a central axis through the hollow structure transverse to thecross section of the molded material and the passages in the moldedmaterial having a central axis through the passage; wherein adjacentsections are connected near the proximal end of each section and theangle formed by the central axis of adjacent connected sections is fromabout 45 to about 90 degrees and the angle formed by the central axis ofthe hollow structure of each section and the central axis of thepassages in the molded material is from about 45 to about 90 degrees;wherein each part is a mirror image of the other and the two parts canbe assembled to form an article having a portion which is symmetrical.Preferably, the molded material of each section forms a consistentcross-section formed along planes perpendicular to the central axis ofthe hollow structure. Preferably, the adjacent elements are connectedtogether near the proximal end at a location from the proximal end thatis equal to about half or less of the linear distance of the centralaxis of two sequential elements of the same orientation while in theassembled state. In some embodiments one part has connected to one end amolded structure comprising one or more asymmetrical portions, such ashelical shaped elements. Preferably, the two parts are assembled.

In another embodiment, the invention is a method comprising: a)introducing two parts of curable material having a high viscosity intoan elongated mixing chamber having a mixer comprising an article of theinvention, an inlet and an outlet, wherein the helical portion isdisposed at the inlet end of the chamber so that the two parts of thecurable material passes through the helical section first; b) applyingsufficient pressure on the material entering the inlet of the chamber tomove the material through the chamber in contact with the mixer underconditions that the two parts are mixed sufficiently to cure and performthe desired function of the curable material; and c) applying the mixedtwo parts of the curable material to one or more substrates. Preferablythe method further comprises: d) contacting a first substrate with asecond substrate with the mixed two part curable material disposedbetween the two substrates; and e) allowing the mixed two part curablematerial to cure and bond the two substrates together.

The articles of the invention can be manufactured in two part molds in acost effective manner. The articles are effective in mixing two partcurable compositions using manual or battery driven application systems.

DESCRIPTION OF THE DRAWINGS

FIG. 1 show two parts of an article of the invention useful as a staticmixer.

FIG. 2 shows the two parts of the article of FIG. 1 from another angle.

FIG. 3 shows an article in two parts one having a helical section.

FIG. 4 is an applicator of FIG. 3 from another angle.

FIG. 5 shows the article of FIGS. 3 and 4 assembled and from its end.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Accordingly, the specific embodiments ofthe present invention as set forth are not intended as being exhaustiveor limiting of the invention. The scope of the invention should bedetermined with reference to the appended claims, along with the fullscope of equivalents to which such claims are entitled. The disclosuresof all articles and references, including patent applications andpublications, are incorporated by reference the all purposes. Thefollowing claims are hereby incorporated by reference into this writtendescription.

The invention relates to an article that can be prepared in two partswhich two parts can be assembled to form an article which is symmetricalor which has a symmetrical portion. The two parts are molded parts andcan be molded using two part molds. Where the article is completelysymmetrical a single two part mold may be utilized to prepare the twoparts. In other words if the two parts are identical and can be mirrorimages of one another a single mold can be utilized. The two parts arecapable of being assembled to form an article which is symmetrical orwhich has a symmetrical portion, if one or both of the two parts containa non-symmetrical section two molds are required. Symmetrical as usedherein means the parts can fit together to form a part that is virtuallyidentical on each side of a plane running through the center from theproximal to the distal end. In general the article comprises: two partswherein each part has two or more sections connected together whereineach section is formed from one or more molded materials wherein themolded materials than the periphery of a hollow structure having aproximal end, a distal end, a cross section and open passages in themolded material on the periphery of the hollow structure, a central axisthrough the hollow structure transverse to the cross section of themolded material and the passages in the molded material having a centralaxis through the passages; wherein adjacent sections are connected nearthe proximal end of each section and the angle formed by the centralaxis of adjacent connected sections is from about 45 to about 90 degreesand the angle formed by the central axis of the hollow structure of eachsection and the central axis of the passages in the molded material isfrom about 45 to about 90 degrees; wherein each part or a portionthereof is a mirror image of the other and the two parts mirrored partscan be assembled to form a symmetrical structure.

The parts of the article of the invention are prepared from any materialthat can be molded in a two part molding system or which can be formedby casting. Exemplary materials include thermoplastics, thermosets,metals and the like. Preferred materials are thermoplastics andthermosets, with thermoplastics preferred. Preferred thermoplasticscomprise any plastic with a glass transition temperature or heatdeflection temperature above room temperature and include polyolefins,polyamides, polystyrenes, acrylonitrile butadiene styrene (ABS), blendsof acrylonitrile butadiene styrene with polycarbonate (PC/ABS) and thelike. Preferred thermosets comprise any thermosetting material with aheat deflection temperature above room temperature and includepolyurethanes, polyureas, acrylics, polyesters, epoxies and the like Thematerials may further comprise fillers, reinforcing agents, internalmold release agents, stabilizers, antioxidants, live retardants and thelike known to those skilled in the art. Exemplary fillers include talc,fumed silica and the like. Preferred reinforcing fibers include polymer,glass, carbon fibers, ceramics, clays and the like.

Two or more parts are assembled to form an article. Each part comprisesa plurality of hollow structures having a proximal end and a distal end.The plurality of hollow structures are affixed to one another near oneend of the hollow structure, designated as the proximal end. The distalend is the end furthest from where the hollow structures are affixed toone another. The point where the hollow structures are affixed togetheris preferably formed during formation of the parts. The hollowstructures have a central axis passing through the center of the moldedhollow structure from the proximal end to the distal end. The moldedmaterial forms walls about the central axis. The walls form atcross-section transverse to the central axis passing through the moldedparts. The cross-section is preferably consistent along the central axisof the hollow parts from the proximal end to the distal end. The crosssection can be any cross section suitable for the desired end use, forexample, irregular, circular, oval, polygonal and the like. Preferablythe cross section is, circular, oval or polygonal. More preferably thecross section is polygonal, even more preferably square or rectangularand most preferably square. As is well known to the skilled artisandraft angles may be engineered into the parts so as to facilitateformation of the parts and removal of the parts from molds.

The walls of each hollow structure preferably contain passagestherethrough that have their own central axis that are transverse to thecentral axis of the hollow structures. The passages through the wallsare of a size and shape to facilitate the articles of the invention toperform the function the article is designed to perform. The passagesthrough the wall preferably have a consistent shape. Exemplary shapesinclude irregular, circular, oval, polygonal and the like. Preferablythe shapes are circular, oval, polygonal with polygonal being morepreferred and square or rectangular most preferred. The passages in thewalls of the hollow structure may pass through the opposite wall of thehollow structure or there may be no passage opposite the passage in thewall of the hollow structure. In some embodiments, it is preferred thatthere is a wall opposite to passages in the wall of the hollowstructure.

The plurality of hollow structures of each part are connected near theproximal end of the hollow structures such that the central axis ofadjacent parts form an angle. The angle is chosen such that the partscan be manufactured using a two-part mold and the articles formed fromthe parts can perform the desired function. Preferably the angle of thecentral axis of the two adjacent hollow structures is about 90 degreesor less. Preferably the angle of the central axis of the two adjacenthollow structures is about 45 degrees or greater, more preferably 60degrees or greater and most preferably about 85 degrees or greater. Mostpreferably the angle is about 90 degrees.

Each hollow section is connected to an adjacent section. They can beconnected in any manner known in the art, for example by mechanicalconnection, adhesive, welding, by a molded or cast in connection. Amolded, or cast, in connection is formed during molding, or casting,where a portion of the material utilized to prepare the parts is formedbetween the adjacent sections which holds the adjacent hollow sectionstogether. Preferably the connection utilized maintains the angle betweenthe central axis of adjacent hollow parts. The connection is locatednear the proximal end of the hollow parts. The distance of theconnection from the proximal end is chosen so as to allow the article ofthe invention to perform its desired function. Preferably, the adjacentelements are connected together near the proximal end at a location fromthe proximal end that is equal to half the linear distance of thecentral axis of two sequential elements of the same orientation while inthe assembled state. Preferably the connection is disposed with respectto the proximal end within 30 percent of the length of the hollowsection, and more preferably about 20 percent of the length.

The two or more parts of the article are adapted to be connected to forman article that is symmetrical or which has a portion that issymmetrical. The parts comprise a plurality of hollow elements. Asufficient number of the hollow elements are utilized to allow theultimate article to perform the function it is designed to perform.Preferably each part comprises two or more hollow sections and morepreferably three or more sections. In some preferred embodiments whenthe two parts are connected together each hollow part has an adjacenthollow part having a central axis parallel to its central axis. The pairof hollow parts form a symmetrical element when the two or more partsare connected. The number of pairs of adjacent hollow parts, hereinafterreferred to as elements, utilized in the article is chosen such that thearticle can perform the function it is designed to perform. The two ormore parts are designed to be connected. They can be connected by anymethod that facilitates the ultimate use of the articles of theinvention. They can be connected by mechanical devices, built in snapfits, interference fit, adhesives, welding and the like. Preferably theparts are connected by built in snap fits or interference fit. In apreferred embodiment the two adjacent sections are square or rectangularand have corners of the square or rectangle adjacent to one another.Such elements from the cross-sectional perspective have two squares orrectangles having adjacent corners, such structure in the central partforms an X. The next adjacent pair of elements have central axisdisposed at the angles described hereinbefore.

One or more of the parts may comprise a non-symmetrical part. Thenon-symmetrical part may be formed by any means capable of preparing thespecific shape. The non-symmetrical part may be attached to thesymmetrical section using any known attachment method, for instanceformed with an integral connection, mechanical methods, welding, anadhesive and the like. Preferably the nonsymmetrical section is moldedat the same time as one or more of the parts and the connection isformed during the molding operation.

In the embodiment wherein articles of the invention are useful as mixersfor flowable material. Each pair of hollow elements with parallelcentral axis can be referred to as a mixing element. In a preferredembodiment wherein the two adjacent elements contact one another along acorner, the adjacent elements form an X in the central section from across-sectional perspective. In a preferred embodiment the passages inthe walls of the hollow section are opposite solid walls along theopposing wall of the hollow section. This feature is utilized to forcethe material passing through a passage in a first hollow wall of asection to move in another direction when it meets the opposing wall ofthe hollow section.

In a preferred embodiment mixers prepared according to the inventioncomprise a nonsymmetrical section. Preferably the nonsymmetrical portionis connected to one of the two or more parts and preferably is formedintegrally to the part it is attached to. The non-symmetrical part canhave any shape that enhances the function of the article, for instancemixing along with the symmetrical port. Preferably the non-symmetricalpart forms a helical path. As used herein element with respect to thenon-symmetrical part, helical element, means a single helical section. Ahelical section comprises a sheet of material that has a bend in itwhich bends about 180 degrees. Material flowing along the helicalsection is turned about 180 degrees. Preferably the end of a helicalsection comprises a straight edge. Preferably the straight edge of onehelical section is rotated 90 degrees from the straight edge of the nextsection. This rotation forces material flowing from one helical sectionto another to be divided by the straight edge of the next helicalsection. If a series of helical sections are used the flowing materialis divided at the beginning of each helical section.

The parts utilized to form the articles of the invention are prepared bymolding. Preferably injection molding. Preferably the mold is a two partmold having actuated slides. The angle between the direction of theactuated slides and the face of each mold is dictated primarily by theangle of the central axis of one hollow element to another within amolded part. In the event that one or more parts comprise anon-symmetrical part a separate mold is utilized for parts of differentshapes. In essence, the moldable material is converted into a flowablematerial. This may be done by heating the material to a temperature atwhich it is molten. The moldable material is injected into a closed moldas described. The mold may be treated with a mold release prior toinjection of the moldable material or the moldable material may containan internal mold release. After injection the moldable material iscooled or allowed to cool and the mold is opened to release the parts.The particular conditions for molding are material dependent and oneskilled in the art would know the appropriate conditions for thespecific moldable material. After removal from the mold any flashing isremoved. The two or more parts are assembled to form the article.

The articles of the invention can be used for a variety of purposes, forexample as mixers, blenders applicators, rheology modifiers, and thelike. In a preferred embodiment the articles are used as static mixersfor mixing viscous materials. Preferably the mixers are used formultipart systems that are reactive and mixed just prior to use, forexample adhesives, coatings, body fillers, foamed plastics or polymers,dispersions and the like. More preferably the articles are used for twopart systems. Preferably the articles are used for adhesive systems.Mixing sys-tems that the mixers can be utilized with typically comprisea mixing tube with a nozzle at the end of the mixing tube. The mixingtubes generally contain a passage for introduction of the ma-terial tobe mixed into the tubes. Disposed in the tubes can be static mixersadapted to mix the parts of the material introduced into the tubes.Typical mixers contain a system for applying pres-sure to the materialintroduced into the tubes to drive the material through the mixer. Thesystem for applying pressure generally includes plungers that push thematerial to be mixed into, through and out of the exit nozzle of themixing tube. Commonly the parts to be mixed are disposed in two separatetubes of the material to be mixed and separate plungers are used fedeach material to push the material from each tube in the mixer.Typically the material in each tube is reactive with the material in theother tube and the components start to cure when mixed. Alternativelythe two parts may be located in the same tube with a membrane or filmseparating the two parts so that they are not in contact in the tube.The smaller volume part is typically located in the inner bag. Often thepart in the inner bag is located alone the side of the tube. Thus themixer needs to dis-perse the smaller part throughout the mixed materialsto achieve even cure of the materials. This system is often referred toas a bag-in-bag system and is often utilized when the volumetric ratioof the two parts is high. This type of system allows the use ofmaterials having odd volumetric ratios. The nozzle of the mixing tubemay be shaped to extrude a bead of the mixed material of a desiredshape. In mixing the pressure applied to the materials being mixed issufficient to overcome the back pressure of the materials being mixed asit passes through the mixer. This sys-tem is especially useful formanual or battery operated mixing systems as such systems are limit-edin the amount of pressure that can be applied to the materials. Suchsystems are typically utilized outside of workshops, for instance bywind shield installers working remotely. Preferably the mixers utilizedapply pressure to the materials moved through the mixer of about 100 psi(6.89 kPa) or greater, more preferably about 150 psi or greater and mostpreferably about 200 psi (1379 kPa) or greater. Preferably the mixersutilized apply pressure to the materials moved through the mixer ofabout 500 psi (3447 kPa) or less and most preferably about 300 psi (206g kPa) or less.

In preferred embodiments mixers of the invention comprise symmetricalsections and non-symmetrical sections. In one embodiment, thesymmetrical sections are referred to as symmetrical X grids. In apreferred embodiment the nonsymmetrical sections comprise helicalelements. The relative number of symmetrical and non-symmetricalelements are chosen to passage of multiple part systems through themixer with adequate mixing and without undue back pres-sure. Adequatemixing means that the parts mix sufficiently to cure evenly throughoutthe applied mixture. Undue back pressure means that the material cannotbe moved through the mixing tubes with the available system for applyingpressure to the mixed materials, for example a manual or batteryoperated mixing system. Preferably the non-symmetrical part of the mixeris disposed at the inlet end of the mixing tube. The inlet end is theend to which the materials to be mixed are introduced. As a corollarythe symmetrical section is disposed nearest to the outlet of the mixingtube that is the nozzle through which the mixed material passes beforeapplication to a substrate. The mixers of the invention preferablycomprise more than one of each type of element. Generally the mixerscomprise sufficient number of helical sections (non-symmetricalsections) to reduce the viscosity of the materials to be mixed, forinstance by shear thinning the materials. The number of X grids,symmetrical sections, are chosen to achieve adequate mixing. Preferably3 or more non-symmetrical sections (helical sections) are utilized.Preferably 4 or more non-symmetrical sections (helical sections) areutilized. Preferably 5 or less non-symmetrical sections (helicalsections) are utilized. Most preferably 5 non-symmetrical sections(helical sections) are utilized. Preferably 3 or more symmetricalsections (X grid sections) are utilized and more prefer-ably 4 or moresymmetrical sections (X grid sections) are utilized. Preferably 6 orless symmetrical sections (X grid sections) are utilized and morepreferably 5 or less symmetrical sections (X grid sections) areutilized. Most preferably 5 symmetrical sections (X grid sections) areutilized. The length of each symmetrical (X grid) section and eachnon-symmetrical section is chosen to achieve the objectives of theformed parts. A skilled artisan would adapt the specific lengths for theparticular application.

The mixers of the invention are adapted to fit in the mixing chambers inwhich they are used. Preferably the mixer fills the mixing chamber toprevent materials to be mixed from passing around the mixer and thus notmixing. Preferably the mixer has the same cross-sectional shape as themixing chamber for this reason. Preferably the cross section is circularor oval. The articles are preferably designed and manufactured such thatwhen the parts are assembled they have the proper cross-sectional shape.The symmetrical section parts are adapted to have outside shapes forthis purpose, the portion of the symmetrical section that will be on theoutside of the part is contains design features to form the appropriatecross-sectional shape.

In some embodiments the symmetrical, nonsymmetrical or both sectionscontain reinforcing structures. Such reinforcing structures can be anyshape or in any location such that the mixer has sufficient structuralstrength to withstand the pressures utilized during mixing. Thereinforcing structures can be rails or ribs. Preferably the ribs orrails are disposed in the direction of mixing. Preferably a plurality ofsuch structures are utilized. The helical section preferably containsribs or rails to support this section. Preferably 2 to 4 rails aredisposed substantially equally about the helical sections.

The mixers of the invention are useful in mixing any multipartcompositions, preferably two part compositions. Such mixers are usefulin mixing highly viscous multipart systems. In preferred embodiments themixers of the invention are useful in mixing systems having a viscosityof about 30,000 centipoises or greater and more preferably about 100,000centipoises or greater. Preferably the mixers of the invention areuseful in mixing systems having a viscosity of about 5,000,000centipoises or less. The mixers can be used to mix any curable systems,for example adhesive systems. The mixers can be utilized to mix two parthybrid systems containing isocyanate functional prepolymers and acrylatecontaining monomers, oligomers or polymers, such systems are disclosedin WO 2012/151086 and WO 2012/151085, incorporated herein by reference.

The separate parts are placed into the mixing system and passed into andthrough the mixing tube to mix the parts. As the mixed parts are passedthrough the nozzle at the outlet such mixed parts are applied to asubstrate. Where the mixed parts are useful as an adhesive twosubstrates are contacted with the mixed parts disposed between them andthe mixed parts are allowed to cure and bond the substrates together.

FIG. 1 shows two parts of an article of the invention 10 useful as amixer known in the art as an SMX mixer. Illustrated are two symmetricalparts 11 and 11′ each having sections 12 and 12′ with different centralaxis 14 and 15 through the molded material forming each section, theangle between the central axis of adjacent sections being theta. Thearrows show how the two parts are placed together. FIG. 2 shows the twoparts from a different angle. Shown are parts 11 and 11′, sections 12and 12′ and central axis 14 and 15. Also shown are a plurality ofpassages 16 in the molded material wherein the passages each havecentral axis 13, disposed through the center of the passages 16. Eachsection has a proximal end 17 and a distal end 18. Dotted line 19illustrates the direction of the plane of the cross section of thesections. Many mixers are adapted to the shape of the mixing chamberinto which they are placed. Common mixers have round or ovalcross-sectional shapes and elongated chambers. The mixing elements areoften adapted in cross-section to the shape of the mixing chamber. Thetaper of the corners of the SMX elements is illustrated, 20. The arrowsshow how the two parts are placed together. FIG. 2 also shows the anglebetween the central axis 15 of a section and the central axis of awindow 13, {dot over (α)}.

FIG. 3 shows a part 11 which is forms a symmetrical article and a part21 which forms a symmetrical article further having a non-symmetricalsection. Part 21 contains a symmet-rical forming portion 22 and anon-symmetrical section 23. FIG. 3 also shows a support rib or rail 24on the non-symmetrical portion. The two parts are shown in an explodedformat. FIG. 4 shows the article of FIG. 3 from a different angle. FIG.5 shows an article shown in FIGS. 3 and 4 from an end section whereinthe two parts are connected and to show the circular cross-sectionalshape of the article adapted for use in a mixing chamber having acircular shape.

One or more as used herein means that at least one, or more than one, ofthe recited components may be used as disclosed. Preferably the curerate is determined by determining the dynamic yield stress, measured byG′ on a rheometer. Preferably the G′ is 6×10⁶ Pa the strength of thecuring adhesive at a designated time.

ILLUSTRATIVE EMBODIMENTS OF THE INVENTION

The following examples are provided to illustrate the invention, but arenot intended to limit the scope thereof. All parts and percentages areby weight unless otherwise indicated.

Mixing Examples

A two part adhesive prepared as described in WO 2012/151086 and WO2012/151085 with the viscosity adjusted by adding additional plasticizerto the recited press flow viscosity of 25 or 30 seconds are placed in abag in bag tube and applied using a battery operated mixer which appliesabout 220 psi (1517 kPa) pressure to the mixture in the tube. A mixerhaving a length of 7 inches is used. The impact energy of the adhesiveand Shore D hardness are measured 20 minutes after cure. The flow ratein grams per minute of the mixed adhesive is measured. The press flowviscosity of the adhesive varies from 25 to 30 seconds. Cure rate ismeasured by impact energy and Shore A hardness. The results are compiledin Table 1.

TABLE 1 Press Mixer flow Impact Flow Diameter viscosity Energy RateShore D Mixer configuration mm (s) (mJ) (g/min) Hardness 5 elementhelical 5 element X-Grid 20 25 6693 1000 23 10 Element Helical 20 252366 84.0 12 Element Helical 16 25 AF 420 Hand Mixed 25 8578 28 X GridOnly 20 25 <1000 NM 5 element helical 5 element X-Grid 20 30 6645 100023 10 Element Helical 20 30 2000 800 X Grid Only 20 30 <1000 >1000 4element helical 5 element X-Grid 20 30 13 3 element helical 5 elementX-Grid 20 30 11 3 element helical 6 element X-Grid 20 30 12 4 elementhelical 6 element X-Grid 20 30 18 4 element helical 4 element X-Grid 2030 11 4 element helical 3 element X-Grid 20 30 CD

AF means applicator failure. NM means not measured. CD means cannotdispense. These results illustrate that the best mixer design is 5helical and 5 X grid elements, as indicated by the high values forimpact energy and Shore A hardness, which are closest to the values forthe hand mixed example.

Impact Energy is measured using the Izod impact test. Press FlowViscosity: The press flow viscosity is determined as the time (seconds)required to extrude 20 grams of adhesive through a capillary. The widthof the capillary is fixed at 0.104 in. (2.6 mm) and the appliedpres-sure is 60 psi (4.1×10⁵ Pa). Unless otherwise noted, all press flowviscosity values were determined at 23+/−1° C.

Parts by weight as used herein refers to 100 parts by weight of thecomposition specifically referred to. Any numerical values recited inthe above application include all values from the lower value to theupper value in increments of one unit provided that there is aseparation of at least 2 units between any lower value and any highervalue. As an example, if it is stated that the amount of a component ora value of a process variable such as, for example, temperature,pressure, time and the like is, for example, from 1 to 90, preferablyfrom 20 to 80, more preferably from 30 to 70, it is intended that valuessuch as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expresslyenumerated in this specification. For values which are less than one,one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate.These are only examples of what is specifically intended and allpossible combinations of numerical values between the lowest value, andthe highest value enumerated are to be considered to be expressly statedin this application in a similar manner. Unless otherwise stated, allranges include both endpoints and all numbers between the endpoints. Theuse of “about” or “approximately” in connection with a range applies toboth ends of the range. Thus, “about 20 to 30” is intended in cover“about 20 to about 30”, inclusive of at least the specified endpoints.The term “consisting essentially of” to describe a combination shallinclude the elements, ingredients, components or steps identified, andsuch other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of theelements, ingredients, components or steps. Plural elements,ingredients, components or steps can be provided by a single integratedelement, ingredient, component or step. Alternatively, a singleintegrated element, ingredient, component or step might be divided intoseparate plural elements, ingredients, components or steps. Thedisclosure of “a” or “one” to describe an element, ingredient, componentor step is not intended to foreclose additional elements, ingredients,components or steps.

1. An article comprising: two parts wherein each part has two or moresections connected together wherein each section is formed from one ormore a molded materials wherein the molded materials form the peripheryof a hollow structure having a proximal end, a distal end, a crosssection and open passages in the molded material on the periphery of thehollow structure, a central axis through the hollow structure transverseto the cross section of the molded material and the passages in themolded material having a central axis through the passages; whereinadjacent sections are connected near the proximal end of each sectionand the angle formed by the central axis of adjacent connected sectionsis from about 45 to about 90 degrees and the angle formed by the centralaxis of the hollow structure of each section and the central axis of thepassages in the molded material is from about 45 to about 90 degrees;wherein each part is a mirror image of the other and the two parts canbe assembled to form a symmetrical structure and one part has connectedto one end a molded structure comprising one or more helical shapedelements.
 2. An article according to claim 1 wherein the molded materialof each section forms a consistent cross-section formed along planesperpendicular to the central axis of the hollow structure.
 3. An articleaccording to claim 1 wherein the cross-section formed by the moldedmaterial is oval, circular or polygonal.
 4. An article according toclaim 1 wherein the molded material comprises metal, thermoplasticresins or thermoset resins.
 5. An article according to claim 1 whereinthe molded material comprises one or more thermoplastic resins orthermoset resins which further comprises one or more fillers,reinforcing fibers or mixtures thereof.
 6. An article according to claim1 wherein the adjacent elements are connected together near the proximalend at a location from the proximal end that is equal to half the lineardistance of the central axis of two sequential elements of the sameorientation while in the assembled state.
 7. An article according toclaim 1 wherein one or both parts have connected to at least one end amolded structure of another shape.
 8. (canceled)
 9. An article accordingto claim 1 wherein the two parts are assembled.
 10. An article accordingto claim 1 comprising three or more elements wherein the cross-sectionof the structure formed by the molded material is a square for eachelement, the elements are connected at opposing corners of the structureand one of the sections further comprises a molded section comprisingmore than one helical structure.
 11. An article according to claim 1wherein each helical element forms a path that rotates about 180 degreesand the starting point of the path of the helical path of adjacentelements is about 90 degrees from the ending point of the adjacentelement.
 12. A method comprising a) introducing two parts of curablematerial having a high viscosity into an elongated mixing chamber havinga mixer comprising an article according to claim 1, an inlet and anoutlet, wherein the helical portion is disposed at the inlet end of thechamber so that the two parts of the curable material passes through thehelical section first; b) applying sufficient pressure on the materialentering the inlet of the chamber to move the material through thechamber in contact with the mixer under conditions that the two partsare mixed sufficiently to cure and perform the desired function of thecurable material; and c) applying the mixed two parts of the curablematerial to one or more substrates.
 13. A method according to claim 12which further comprises d) contacting a first substrate with a secondsubstrate with the mixed two part curable material disposed between thetwo substrates; and e) allowing the mixed two part curable material tocure and bond the two substrates together.
 14. A method according toclaim 12 wherein the mixer comprises one or more helical elements andtwo or more hollow elements wherein the helical portion is disposed atthe inlet end of the mixing chamber so that the two parts of the curablematerial passes through the helical section first.
 15. A methodaccording to claim 12 wherein the mixer has from about 3 to about 5helical elements and from about 3 to about 6 hollow elements.
 16. Amethod according to claim 12 wherein the viscosity of the two part ofthe curable material is from about 30,000 to about 5,000,000 Pa·s.
 17. Amethod according to claim 12 wherein the pressure applied to the twoparts of the curable material is from about 150 to about 500 psi.
 18. Amethod according to claim 12 wherein the two part curable material iscontacted at a volumetric ratio of 1:1 to 100:1.
 12. A method accordingto claim 12 wherein the two parts of the curable materials areintroduced from a single tube having the lowest volume part enclosed ina bag within the highest volume part.